CN1860187B - 涂覆粘合剂的刚玉喷撒的装饰纸 - Google Patents

涂覆粘合剂的刚玉喷撒的装饰纸 Download PDF

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CN1860187B
CN1860187B CN2003801104718A CN200380110471A CN1860187B CN 1860187 B CN1860187 B CN 1860187B CN 2003801104718 A CN2003801104718 A CN 2003801104718A CN 200380110471 A CN200380110471 A CN 200380110471A CN 1860187 B CN1860187 B CN 1860187B
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迪特尔·德林
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Abstract

本发明涉及耐磨损粒子，优选用干燥的粘合剂涂敷。

Description

涂覆粘合剂的刚玉喷撒的装饰纸 
本发明涉及耐磨损粒子，其用于具有耐磨损表面的装饰纸的生产方法。本发明还涉及由此制备的装饰纸。美国专利第4,940,503号公开了一种方法，其中可选择地将耐磨损粒子喷撒到经三聚氰胺树脂浸渍的轮廓纸上或经三聚氰胺树脂浸渍的装饰纸上。然后将轮廓纸和装饰纸挤压到一起，制得具有耐磨损表面的装饰纸。但是，与其它方法相比，用该方法获得的耐磨损性能较低。 
WO 00/44576 A1公开了另一种方法，其中向经浸渍的装饰纸上喷撒耐磨损粒子如刚玉。然后将纤维和树脂一起应用并挤压该层状体系。用该方法获得的耐磨损性能也是相对较小。 
WO 00/44984 A1公开了一种方法，其中向装饰纸上喷洒含耐磨损粒子如刚玉或碳化硅的特殊分散体。该装饰纸随后用于制造叠层压地板镶板(Laminat-Fuβbodenpaneels)。通过该方法能获得高的磨损值，但缺点是设备成本高，因为必须处理过量的分散体，必需用于直接喷撒的设备，要确保分散体的持续混合，并且最后必须花费高的干燥费用。 
本发明的目的是创造一种具有高耐磨性的可以简单的方式制备的装饰纸。 
根据本发明，用助粘剂涂覆耐磨损粒子，并向经浸渍的装饰纸或经浸渍的轮廓纸上喷撒耐磨损粒子。然后将装饰纸和轮廓纸相互挤压。当向装饰纸上喷撒耐磨损粒子后，可向例如纤维上而不是向轮廓纸上喷撒，以及应用树脂，以在挤压过程中保护压力机(Presse)不受耐磨损粒子的损伤。 
与从WO 00/44984 A1所知的喷撒方法相比，使用本发明的喷撒方法能够使耐磨损材料分布更均匀。同时设备成本也更低。用粘合剂涂覆粒子非常简单，因为只需在相应的浴槽中暂时浸渍粒子。与根据WO00/44984 A1所必需的设备成本相比，该方法在技术上显然成本更低。 
为能够特别准确地量取耐磨损粒子，优选在喷撒前干燥具有粘合剂的粒子。在干燥的和因而非常好地量取的状态下，粘合剂特别完全地涂覆耐磨损粒子，从而得到特别好的磨损值。为此目的，首先在基本由粘合剂组成的液体中浸渍耐磨损粒子。或者用粘合剂喷涂耐磨损粒子。与根据WO 00/44984 A1所需的设备成本相比，该方法的成本仍然更低，因为不必注意量取和循环。然后粒子经干燥成为特别好用的粒子。向装饰纸上或轮廓纸上喷撒经干燥的、具有粘合剂的耐磨损粒子。优选地，为喷撒提供具有特别是不规则运行(verlaufen)的具有空腔的辊。但是，空腔的深度基本保持不变。从上面向辊上喷撒具有粘合剂的耐磨损粒子并到达空腔内。通过刮刀刀片去掉过量的材料，即过量的具有粘合剂的耐磨损粒子。然后，旋转的辊到达刷子，其扫除具有粘合剂的耐磨损粒子。 
关于刷子，优选具有刚毛的旋转辊，以均匀地扫除具有粘合剂的耐磨损粒子。以此方式，向装饰纸或轮廓纸上均匀地喷撒耐磨损粒子，并且取决于所需的磨损等级，优选的量为18-25g/m2。粒度为直径50-200μm、优选为90-130μm。若选择较小的直径，则消耗较多量的耐磨损粒子以及粘合剂。若选择较大的直径，则耐磨损粒子能穿透通常采用的轮廓纸并损伤压力机。 
在用耐磨损粒子喷撒纸即装饰纸或轮廓纸之前，将各自的纸幅牵引通过三聚氰胺树脂或含三聚氰胺树脂的混合物。通过粘合剂使刚玉粒子和/或碳化硅粒子嵌入树脂基体中。否则，在耐磨损粒子与树脂和/或树脂基体之间将存留光学可见的界面，导致泛灰。若不用粘合剂， 耐磨损粒子可从基体中被拉出，导致低的磨损值。 
特别优选向装饰纸上喷撒耐磨损材料，因为实践证明，当向轮廓纸上直接喷撒耐磨损粒子时，耐磨损粒子更易损伤压力机。 
最终将轮廓纸和装饰纸合在一起并挤压，从而使耐磨损粒子形成中间层。在挤压过程中表面温度优选为180-185℃。通常采用的压力为20-35巴。所述温度有利于树脂材料的固化。所述压力有利于使层状体系所含的水保持液体状。否则水将以气体形式逃逸，从而造成粗糙的表面。通过高压能进一步确保非常均匀的表面。 
特别优选装饰纸的重量为20-200g/m2、优选为20-60g/m2、特别优选为25-40g/m2，以用少量的树脂处理。优选用丙烯酸酯或含丙烯酸酯的分散体来填充装饰纸，以进一步减少所需的较昂贵的三聚氰胺树脂的量。特别地，从两面将丙烯酸酯和/或分散体挤压入装饰纸，以确保其进入纸的内部。WO 02/079571 A1公开了适合的组合物以及方法，以使的丙烯酸酯和/或分散体进入本发明纸的内部。 
在喷撒过程中，优选在纸(轮廓纸或装饰纸)的侧面提供有漏斗，以收集并清除过量的耐磨损粒子。这样，如果耐磨损粒子过量喷撒在侧面上，它们能被再利用。 
与从WO 00/44984 A1所知的喷撒方法相比，该方法避免了高的设备费用。与作为耐磨损材料的刚玉相结合，本发明首次成功地用暗的装饰纸提供明亮的表面。 
优选刚玉或氧化铝粒子作为耐磨损粒子，因为其它材料如碳化硅能被更容易地嵌入树脂基体中。与刚玉或氧化铝相比，碳化硅的缺点在于特别是在亮的图案上其为相当可见的暗粒子。所以，由于外观原因碳化硅较不适合。 
在浸渍时，通常给装饰纸提供相对装饰纸100-120％重量份的树脂。因此，如果装饰纸的单位面积重量为例如100g/m2，则使用100-120g树脂。但是，如果装饰纸的重量仅为30g/m2，并且如果将丙烯酸酯或含丙烯酸酯的分散体挤压入纸内时，能使浸渍所需的树脂的量减少到45-55％重量份。 
也能使用混合树脂代替三聚氰胺树脂。通过该混合树脂由70-80％重量份的脲树脂和20-30％重量份的三聚氰胺树脂组成，以此方式降低树脂的成本。优选用混合树脂浸渍装饰纸，因为能够节省成本。优选用纯的三聚氰胺树脂浸渍轮廓纸，以提供所需的表面性能。对污点形成的不敏感性以及对化学药品的耐受性对表面特别重要。同时三聚氰胺树脂也对表面起到特别好的防潮作用。 
因为向纸上喷撒刚玉，结果得到刚玉位于一面的装饰纸。这能通过显微镜确定。另外，可在制成品中发现涂覆耐磨损粒子的粘合剂。 
作为粘合剂，优选基于硅烷的，因为这些粘合剂特别适合在一方面粘着刚玉或氧化铝，在另一方面以所需的方式与所用的树脂相互作用，以得到所需的粘着和因此所需的耐磨损性。 
原则上其它粘合剂也是适合的。已发现氨基-硅烷粘合剂特别适合。 
附图说明：
图1表示用于向纸上喷撒耐磨损粒子的装置； 
图2表示所制备的纸； 
图3表示具有所生产纸的镶板。 
用硅烷粘合剂涂覆直径为90-130μm的刚玉的耐磨损粒子1并干燥。如图1在截面所示，耐磨损粒子1现在是自由流动状态并被喷撒到辊2上。辊2具有在表面上的没有显示的空腔。通过辊2沿箭头3逆时针地缓慢旋转，被喷撒的粒子到达与有开口端的辊2配合的刮刀刀片4。通过刮刀刀片确保耐磨损粒子1均匀和完全地填充空腔。从此处，耐磨损粒子被传送到在该实施例中沿箭头6的方向顺时针快速旋转的刷子5。耐磨损粒子被完全扫出空腔并到达装饰纸7的表面。通过适当旋转的辊8和辊9在辊下牵引装饰纸。在此之前不久，用25％重量份的三聚氰胺树脂和74％重量份的脲树脂组成的混合物浸渍装饰纸7。装饰纸的单位面积重量为30g/m2且内部有丙烯酸酯。在浸渍过程中应用的树脂为15g每平方米纸。
以此方式能够用耐磨损粒子特别均匀地喷撒纸。在此耐磨损粒子1与有印刷图案的面贴附。 
然后，将经三聚氰胺树脂浸渍的轮廓纸10置于耐磨损粒子1上，之后在30巴的压力和180℃的温度的供热条件下挤压该层状体系。结果得到图2示意的结构，其中耐磨损粒子现在被牢固地固定在树脂基体11中。耐磨损粒子1位于一个平面。 
将具有耐磨损层的装饰纸12与由衍生木质制品如HDF或MDF组成的的基板13和垫纸14挤压。然后锯出通常20至40cm宽和80至160cm长的所需尺寸的镶板，并在侧面提供有配合装置例如凹槽15和舌片16。优选地，凹槽和舌片还有未显示的能以正向配合互相联接两镶板的互锁装置，从而互锁平行于镶板的表面。这种互锁装置见于例如WO 02/079571 A1中。 
特别地，垫纸具有低的单位面积重量20-60g/m2并优选有丙烯酸酯，并且优选在挤压前用脲树脂或主要含脲树脂的混合物浸渍。因为使用了与其它树脂相比价格相对较低的树脂，用该方法，应用垫纸所需的成本最小化。该垫纸保护镶板免于翘曲。 

Claims (27)

1.一种层压镶板用纸，其中该纸用树脂浸渍，并且包括耐磨损粒子，其特征在于所述耐磨损粒子具有基本由粘合剂组成的涂层，其中被涂覆的耐磨损粒子嵌入到所述树脂基体中。
2.如权利要求1所述的纸，其特征在于所述粘合剂是干燥的。
3.如权利要求1所述的纸，其特征在于所述耐磨损粒子的直径为50至200μm。
4.如权利要求1所述的纸，其特征在于所述耐磨损粒子的直径为90至130μm。
5.如权利要求1所述的纸，其特征在于所述耐磨损粒子被硅烷粘合剂涂敷。
6.如权利要求1所述的纸，其特征在于所述耐磨损粒子被氨基-硅烷粘合剂涂敷。
7.如权利要求1所述的纸，其特征在于所述耐磨损粒子由碳化硅组成。
8.如权利要求1所述的纸，其特征在于所述耐磨损粒子由氧化铝组成。
9.如权利要求1所述的纸，其特征在于所述耐磨损粒子由刚玉组成。
10.如权利要求1所述的纸，其特征在于所述纸的重量为20至200g/m2。
11.如权利要求1所述的纸，其特征在于所述纸的重量为20至60g/m2。
12.如权利要求1所述的纸，其特征在于所述纸的重量为25至40g/m2。
13.如权利要求1所述的纸，其特征在于用丙烯酸酯或含丙烯酸酯的分散体填充纸的内部。
14.如权利要求1所述的纸，其特征在于将所述纸与轮廓纸和/或纤维挤压，其中耐磨损粒子位于所述纸和轮廓纸和/或纤维之间。
15.如权利要求1所述的纸，其特征在于所述纸是装饰纸。
16.如权利要求1所述的纸，其特征在于所述耐磨损粒子位于一个平面内。
17.如权利要求1所述的纸，其特征在于所述树脂含三聚氰胺树脂和脲树脂，并且其中所述纸有图案。
18.如权利要求17所述的纸，其特征在于将所述纸与轮廓纸或纤维挤压，其中用纯的氨基树脂浸渍所述轮廓纸或纤维。
19.制备有耐磨损表面的纸的方法，其中：
提供纸；并且
用树脂浸渍所述纸；
其特征在于，在干燥条件下向所述纸上喷撒具有基本由粘合剂组成的涂层的耐磨损粒子，并通过在供热条件下与另一经浸渍的纸或与纤维和树脂挤压来固化所述树脂。
20.具有根据权利要求1所述的纸的层压镶板，其特征在于在基板上应用所述纸。
21.如权利要求20所述的层压镶板，其特征在于所述基板由衍生木质制品组成。
22.如权利要求21所述的层压镶板，其中所述衍生木质制品为HDF或MDF。
23.如权利要求20所述的层压镶板，其特征在于所述基板的反面具有垫板。
24.如权利要求23所述的层压镶板，其特征在于所述垫板的重量为20至60g/m2。
25.如权利要求20所述的层压镶板，其具有侧面固定的配合元件以及其它配合元件，以使两层压镶板能够以相对于镶板表面垂直的方向、和以相对于镶板表面平行的方向相互连接。
26.如权利要求25所述的层压镶板，其所述侧面固定的配合元件包括凹槽和舌片。
27.如权利要求23所述的层压镶板，其中所述垫板具有脲树脂。
CN2003801104718A 2003-09-30 2003-10-11 涂覆粘合剂的刚玉喷撒的装饰纸 Expired - Lifetime CN1860187B (zh)

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